Method for producing an adhesive fastening element made of plastic and device for carrying out said method

ABSTRACT

The invention relates to a method for producing an adhesive fastening element made of plastic, comprising a support part ( 10 ) from which project a plurality of stem parts ( 12 ) and where a head part ( 14 ) is arranged at each of the ends of said stem parts, the ends opposing the support part ( 10 ). According to the invention, a moulding tool ( 16 ) is used for moulding the stem parts ( 12 ), which extends between the support part ( 10 ) and the head parts ( 14 ) and is removed in a de-moulding process once the stem parts ( 12 ) have been moulded. The invention is characterized in that the head parts ( 14 ) are formed without the use of moulding tools due to the surface tension of the used plastic material and, consequently, there is no need for a specific moulding tool for forming the head parts, as is characteristic of the prior art.

The invention relates to a method for producing an adhesive fastening element made of plastic which has a support part, from which a plurality of stem parts projects, on whose ends opposite the support part there is one head part at a time, for molding the stem parts a molding tool being used which extends between the support part and the head parts and which is removed after molding the stern parts in a mold removal process. The invention relates furthermore to a device for carrying out said method.

Such touch fastener elements, which also include mechanical fastening elements, with touch fastener elements made in a complementary manner form a fastener which can be repeatedly opened and closed, hooks or mushroom-like fastener elements interacting with loop-like fastener elements of another touch fastener element with the formation of a touch fastener. Solutions are also known in which the same touch fastener elements of two different touch fastener elements interact with one another (hermaphroditic fastener).

Thus DE 699 22 264 T2 discloses supplying a belt-like support part with a plurality of projecting stem parts to a molding gap between heatable molding rolls, into which by way of an extrusion means an additional molding belt of plastic material can be supplied which as the actual molding tool with mold recesses shapes the hot stem ends of the stem parts into head parts in order to obtain a mushroom-like touch fastener element in this way. Since the indicated head parts in the known solution are formed from the plastic material of the stem parts, in this respect the head parts are of smaller dimension due to low material charging in the free and therefore projecting head surface which is available for interlocking; this can adversely affect the required adhesion forces.

Conversely, U.S. Pat. No. 6,180,205 B1 proposes a production method using a molding roll in which a belt-like support part can be connected to a plurality on touch fastener elements which can be dimensioned to be relatively large. For this purpose, the molding roll on its outer periphery has hook-shaped mold recesses into which plastic material is pressed to fill the mold by way of a first extruder means. Excess plastic material on the outer peripheral side of the molding roll is removed by means of a cutting removal means which is technically referred to as a doctor blade. By means of a second extruder means which is located downstream in the production direction the support part material is then applied and permanently connected to the hook-shaped fastener elements during the cooling process of the roll. A stripper roll then removes the finished fastener element from the molding means. Due to the hook geometry difficulties can arise during the mold removal process and, furthermore, a relatively high proportion of plastic scrap is formed in the production process due to use of the indicated doctor blade.

WO 2006/099000 A2 furthermore discloses spraying a belt-like conveyor device on its upper strand side with droplets of plastic material, the plastic material being molded based on its surface tension into hemispherical shell bodies which then are permanently connected on their arching top to a belt-like support part with the formation of a touch fastener element. In a development of this solution it is also possible, in the manner of thickened stem parts, to supply a belt-like support part which on its top bears grain-shaped agglomerates as the stem parts onto which then the hemispherical head parts can be placed. The touch fastener element which is produced in this way and which is designed to be used in particular as a fastener for baby diapers or incontinence diapers is, however, made relatively stiff and leaves much to be desired with respect to the fastener characteristics. US 2006/0220271 A1 discloses a comparable solution which, however, calls for a molding tool in the form of a molding roll with the corresponding mold recesses instead of a belt for production of hemispherical fastener elements. In this respect production of stem parts between the head parts and support part is not done with this known solution.

U.S. Pat. No. 5,785,784 discloses a production method for producing a belt-like support part on which there are a plurality of projecting stem parts. In a downstream production step the free stem ends are heated and then thicken as a result of the surface tension of the plastic material in particular into a hemispherical head part. If, in a continuation of the known solution, the head parts which can be produced in this way are reshaped by means of a so-called calander rolling method, widened head part geometries are formed which with respect to the low material charge are made relatively small and are widened in the direction of the earlier rolling direction.

DE 693 11 107 T2 discloses a generic method for producing a plastic touch fastener element with a base as a support part and with several stem parts which each have a proximal end projecting from the support part and a distal end which is provided with a head part, with the following method steps:

-   -   a) providing a permanent support part mold as a first molding         tool for molding the support part of the touch fastener element;     -   b) providing a non-permanent stem part mold as a second molding         tool with several passages for molding the stem parts;     -   c) providing a permanent head part mold as the third molding         tool with several cavities for molding the head parts;     -   d) attaching the non-permanent stem part mold to the support         part mold such that the passages of the stem part mold are in a         fluid connection to the cavity of the support part mold and         attaching the head part mold to the non-permanent stem part mold         such that the cavities of the head part mold are in a fluid         connection to the passages of the nonpermanent stern part mold.

By injecting a suitable molten plastic into the three indicated molding tools in conjunction with curing of the plastic, a plastic touch fastener element is formed, by separation of the head part mold from the support part mold together with removing the non-permanent stem part mold the touch fastener element which has been removed from the mold in this way being present as a commercial product. The known solution moreover relates to a molding device which is characterized by three different molding tools, formed from the permanent support part mold, the permanent head part mold and the nonpermanent stem part mold. Due to the plurality of individual molds which must be made available and which must be handled in the production process, a certain preparation and production effort is necessary.

Based on this prior art, the object of the invention is to further improve the known solutions while retaining their advantages, especially at low production costs to devise a reliable touch fastener element which can be adjusted in wide ranges in terms of its fastening behavior.

This object is achieved by a method with the features of claim 1 and a device with the features of claim 6.

The method according to the invention is characterized in that the head parts of the touch fastener element are formed free of a molding tool as a result of the surface tension of the plastic material used. Since according to the invention the head parts can be formed themselves during the solidification process, an independent expensive molding tool for forming the head parts, as is shown in the prior art, can be completely dispensed with. In this respect the method can also be carried out very efficiently since only two molding tools need be managed.

On the one hand, it is possible by injecting or pouring plastic material into a molding tool to first produce the support part as the basis of the touch fastener element, then to introduce the molding tool for the stem parts as a lost mold by the pertinent molding tool being placed on the top of the support part in order to then in another process step deliver the stem parts into the cavities or mold recesses of the molding tool as a lost mold, a certain material excess for each stem part projecting over the assigned cavity of the lost mold, in order to then allow the head part itself to be formed as a result of the surface tension of the material used. For the separate attachment step of the stem part together with the head part the plastic material of the support part can be made already cured or accordingly only partially cured. After molding the stem parts in the assigned molding tool, and after automatic molding and curing of the head parts, on its free flat top the molding tool can then be withdrawn from the then cured stem parts and the touch fastener element is thus finished. By making the molding tool for the stem parts as a lost mold an economical alternative is devised which, compared to other solid molding tools for touch fastener elements, allows a more efficient production process.

In one alternative preferred embodiment of the solution according to the invention, it is provided that a suitable liquid plastic material be placed in the permanent molding tool as part of the molding device with the formation of an immersion bath, in particular injected, in order to then press the nonpermanent molding tool with its mold recesses for the stem parts from overhead into this immersion bath. Preferably, there are actuators suitable for this purpose which partially introduce the stem part molding tool in the immersion bath. The still liquid or partially plasticized plastic material then rises, viewed in the vertical direction, through the mold recesses of the molding tool made as a lost mold and forms the stem parts in doing so. If the molding tool is pressed still further into the immersion bath, then plastic material is displaced up out of the mold recesses so that in this respect the excess plastic material collects on the top of the molding tool for the stern parts and as a result of surface tension then the dome-shaped or hemispherical head parts in turn form automatically. After curing of the touch fastener element then again, as already shown, the molding tool for the stern parts is removed as a lost mold and the touch fastener element is completed for its further use and can be removed from the molding device.

On the one hand, the two molding tools being used at the time form a stationary molding tool for the support part, and, on the other hand, a lost mold for the stem parts. Preferably, the two molding tools are made in the manner of injection molding tools which can be economically implemented and which increase the process reliability with respect to its mechanically simple structure. If in the prior art the known production devices of complex structure can be accurately triggered with respect to temperature, this is no longer necessary with the use of the method according to the invention; this in turn helps cut production costs and reduces the total price of the finished touch fastener product.

With the method according to the invention, demanding plastic materials such as acrylate material can also be used for the entire touch fastener element or parts of it. In particular, in the initially named two-stage process, for example, the support part can be produced from an acrylate material and the stem parts to be attached together with the head parts which are themselves produced could consist of a thermoplastic material so that on the one hand a relatively strong support would be achieved and the fastener elements themselves in the form of the respective stem part together with the pertinent head part made correspondingly flexible could be conductive to good bottom engagement of the corresponding touch fastener element, whether in the form of loop material or in the form of mushroom-like interlocking elements.

The molding device according to the invention for carrying out the production process is made in the manner of an injection molding tool and has a corresponding mold recess for inserting the film-like molding tool which accordingly molds the stem parts of the touch fastener element. The other molding tool is preferably made modular so that worn components can be easily replaced by new ones and the film-like molding tool is made at any rate as a lost part which is to be replaced again; this has the advantage that with respect to the thin stem cross sections a new molding tool is always available again; this improves the reproduction accuracy for the desired stem cross sections.

Other advantageous embodiments of this invention are the subject matter of the other dependent claims.

The solution according to the invention is detailed below using one exemplary embodiment. The figures are schematic and not to scale.

FIG. 1 shows a cross section through a molding device;

FIG. 2 shows a top view of part of the molding device as shown in FIG. 1;

FIG. 3 shows in a perspective top view the modular molding device as shown in FIG. 1 in the assembled state.

The method according to the invention described below is used to produce a plastic touch fastener which has a belt-like support part 10 from which a plurality of stem parts 12 projects, on whose ends opposite the support part 10 there is one head part 14 at a time. For the sake of simplicity the figures relate to a touch fastener element with a total of six fastener elements, each consisting of a stem part 12 with a head part 14 which are paired next to one another in rows of three. This yields a touch fastener element with an almost square support part as the support belt 10. In an expansion of the arrangement, depending on the type of molding devices used at the time, moreover, any number of fastener elements, of course, can be devised for a touch fastener element. Furthermore, spherical molds as head parts 14 are disclosed and are formed with the surface tension of the plastic material used by itself when the plastic cools or solidifies.

The method according to the invention is characterized in that for molding of the stem parts 12 a molding tool 16 is used which extends between the support part 10 and the head parts 14 according to the representation of the molding tool as shown in FIG. 1, after molding the stem parts 12 the molding tool 16 being removed in a separate mold removal process. The molding tool 16 can be, for example, a thermoplastic film which in the cold state forms stable mold recesses 18 for the stem parts 12 to be molded and is heated for removal from the mold such that in the elastic state it can be withdrawn from the molded stem parts 12 with the head parts 14. The thermoplastic film can be preferably one of low density polyethylene (LDPE) material. In this exemplary embodiment, as shown in the figures, the mold recesses 18 viewed in cross section are made round so that cylindrical stern parts 12 form in this way; here, however, other cross sectional shapes would be conceivable depending on the geometry of the mold recesses 18, for example, for obtaining stem parts 12 with a polygonal cross section or oval cross section.

The length of the sterns 12 is oriented in turn to the thickness or to the insertion height of the film which forms the molding tool 16 and which in the cold state can be made rigid; but it can also be a flexible film. In particular, thermoplastic LDPE film in the cold state is suitable for an injection molding process in which the touch fastener element is produced by injection molding and for removal from the mold the film should be heated to a value (for example, 80°) until it is stretchable, such that it can be withdrawn from the finished fastener element without damaging it and especially without tearing the heads 14 off. The withdrawn molded film as a molding tool 16 could then be delivered again to an extruder which is not detailed and which then generates a new molding tool 16 again. The film can also be extruded as a whole and could then be perforated accordingly to form the mold recesses 18 for the stem parts 12.

The molding tool 16 could also, however, be a film which can be chemically, thermally or biologically dissolved. In turn, it should form stable mold recesses 18 in the actual mold state and could then, however, be dissolved for removal from the completely molded stem parts 12 by means of a solvent. For a film which dissolves in this way especially a water-soluble film formed from gelatin materials or polyvinyl acetate would be feasible. The plastic materials for the actual touch fastener element can be thermoplastics such as, for example, polyamide, polypropylene or polyethylene. But preferably the touch fastener element is formed from a UV-crosslinkable acrylate material; this results in an especially resistant, durable fastener material.

The molding device shown in FIGS. 1 and 2 is detailed in FIG. 3, in particular, is designed as an injection molding tool. Together with the molding tool 16 designed as an insert part, the molding device has another molding tool 20 which can be modularly assembled from individual base blocks. Thus, underneath the molding tool 16 designed as an insert part, there is a square mold block which has a concave mold depression for molding the rectangular support part 10. The molding tool 16 is placed congruently relative to the common longitudinally axes over this mold block and this combination is then assembled from four holding blocks 26 which are screwed against one another and to the mold block.

This composite block of individual holding blocks 26 with the insert part 16 can also be arranged in the manner of a peripheral belt in a row repeatedly in succession and/or next to one another so that in this way mass production could be done as well as production of larger touch fastener elements with a plurality of fastener elements greater than six. In order to achieve a stable molding device combination for injection molding, preferably aluminum material is used for the molding device and for its components. For perforating the molding tool 16 a water jet cutting process which is not detailed can be used. Furthermore, to thoroughly harden the acrylate plastic for the touch fastener element, a thermal device which is not detailed can be used or there can be UV crosslinking.

Furthermore, it is possible, by means of injector nozzles which are not detailed, to fill the mold recess within the molding tool 20 viewed in the direction of looking at FIG. 1 from underneath with a type of plastic material in order to then in a downstream production step introduce a different plastic material for the stem parts 12 and the support part 10 from the top. In this way, then the support part 10 can be made from especially hard acrylate material and the stem parts 12 together with the head parts 14 could consist of a different thermoplastic material. In the reverse case, the stem parts and the head parts 12, 14 could be formed from hard acrylate material.

In the embodiment as shown in FIG. 1, first of all a suitable liquid plastic material is placed in the molding device with the formation of a type of immersion bath, in particular injected, and then, viewed in the direction of looking at FIG. 1, the molding tool 16 with its mold recesses 18 is pressed on from overhead with a suitable actuator (not shown). The then still liquid or partially plasticized plastic material then rises through the mold recesses 18 of the molding tool 16 toward the top viewed in the direction of looking at FIG. 1 and in this way forms the stem parts 12. The excess plastic material then collects on the flat top of the molding tool 16 and, as a result of the surface tension, hemispherical head parts 14 form in this way. After curing of the touch fastener element, then, as already shown, the molding tool 16 is removed as a lost mold.

The indicated film as the molding tool 16 can consist of an elastomer material such as silicone, and can have, in particular, elastic properties. But it would also be conceivable to use a thin-walled aluminum foil as the molding tool 16 which can be torn or cut for the process of removal of the touch fastener element from the mold. Elastically flexible gauze solutions are also conceivable which can also remain on the touch fastener element depending on its definable elasticity. The elastically flexible material, in particular gauze material, is compressed along the longitudinally axis of the respective stem part 12, for example, by pressing a corresponding touch fastener element onto the foil in this way, between the top of the remaining foil and bottom of the head part material a gap can still remain which the respective interlocking means of the corresponding touch fastener element can engage by interlocking.

If the molding tool 16 is provided on its top with the corresponding geometries, for example, in the form of dome-shaped recesses (not shown) a solid spherical head can also be obtained as the head part 14. If a concentric enclosure edge (not shown) is introduced into the top of the molding tool 16 to the respective longitudinally axis of the stem, plastic material displaced in the solidification process can penetrate into the pertinent mold groove so that on the bottom of the head part 14 which is to be formed at the time an annular projection arises which later helps improve the interlocking situation for the overall touch fastener. In this respect therefore there is also a plurality of possibilities for shaping the respective head part 14 on its bottom adjacent to the molding tool 16. It would also be possible to obtain various configuration possibilities for a touch fastener element with only one molding tool 16 from the bottom. 

1. A method for producing an adhesive fastening element made of plastic which has a support part (10) from which a plurality of stem parts (12) projects, on whose ends opposite the support part (10) there is one head part (14) at a time, for molding the stem parts (12) a molding tool (16) being used which extends between the support part (10) and the head parts (14) and which is removed after molding the stem parts (12) in a mold removal process, characterized in that the head parts (14) are formed free of molding tools as a result of the surface tension of the plastic material used.
 2. The method according to claim 1, characterized in that the molding tool (16) is a thermoplastic film which in the cold state forms stable mold recesses (18) for the stem parts (12) to be molded and is heated for removal from the mold such that in the elastic state it can be removed from the molded stem parts (12) with the head parts.
 3. The method according to claim 2, characterized in that the thermoplastic film is a film of low density polyethylene material.
 4. The method according to claim 1, characterized in that the molding tool (16) is a film which dissolves chemically, thermally or biologically, which in the mold state forms stable mold recesses (18) for the stem parts (12) to be molded, and which is dissolved for removal from the stem parts (12) by means of a solvent.
 5. The method according to claim 4, characterized in that the dissolving film is a water-soluble film consisting of gelatine or polyvinyl acetate.
 6. A molding device for carrying out the production process according to claim 1, characterized in that there is another molding tool (20) into which the film-like molding tool (16) can be inserted.
 7. The molding device according to claim 6, characterized in that at least the other molding tool (20) is made as an injection molding tool.
 8. The molding device according to claim 6, characterized in that the other molding tool (20) has a recess whose height is such that at least the support part (10) with the stem parts (12) and the molding tool (16) can be held.
 9. The molding device according to claim 8, characterized in that the bottom of the recess is made flat for forming the support part (10). 